Automated Annular Composite Forming with Roller Compaction
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Solution Overview
Problem
Current methods for fabricating annular shaped composite structures are costly and time-consuming, often resulting in less than desired strength characteristics, particularly due to the need for hand lay-up and intermediate debulkings.
Innovation Solution
An apparatus featuring an annular shaped tool with a forming head that allows for the automated formation of continuous or discontinuous material into stiffened annular structures, enabling continuous wrapping and roller compaction of ply layers on a constant cross-section, eliminating the need for intermediate debulks and achieving superior specific strength characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If hand lay-up with intermediate debulkings is used to fabricate annular composite structures, then the process can be completed with traditional methods, but the production time is significant and cost is high
Solution Approach 1:
The patent replaces the manual hand lay-up process with an automated fiber placement system that uses computer-controlled mechanisms to deposit fiber layers. This substitution of mechanical automation for manual labor directly reduces production time while maintaining manufacturing capability, resolving the contradiction between ease of manufacture and productivity.
Solution Approach 2:
The patent implements preliminary debulking actions during the fiber placement process itself, rather than requiring separate intermediate debulking steps after lay-up. The system pre-compresses and consolidates layers as they are being deposited, eliminating the need for subsequent debulking operations and thereby reducing overall production time while preserving manufacturing quality.
2Ease of manufacture
If hand lay-up with intermediate debulkings is used to fabricate annular composite structures, then the process can be completed with traditional methods, but the production cost is high
Solution Approach 1:
The automated fiber placement system replaces costly manual hand lay-up operations with computer-controlled mechanisms. This substitution reduces labor costs and material waste associated with manual processes, thereby lowering production costs while maintaining the ability to manufacture complex annular structures.
Solution Approach 2:
The system incorporates self-adjusting and self-monitoring capabilities that automatically optimize fiber placement and consolidation parameters during manufacturing. This self-service functionality eliminates the need for extensive manual intervention and quality checks, reducing both labor costs and production errors, thereby addressing the high production cost issue.
3Ease of manufacture
If hand lay-up with intermediate debulkings is used to fabricate annular composite structures, then the process can be completed with traditional methods, but the strength characteristics are less than desired
Solution Approach 1:
The automated fiber placement system provides precise control over fiber orientation, layer alignment, and consolidation pressure that cannot be achieved with manual hand lay-up. This mechanical automation ensures consistent fiber-to-resin ratios and eliminates voids or delamination, resulting in superior strength characteristics while maintaining manufacturing capability.
Solution Approach 2:
The system performs preliminary consolidation and debulking actions during the fiber placement process itself, ensuring proper layer bonding and void elimination before subsequent layers are added. This preliminary action prevents defects that would compromise strength, achieving desired strength characteristics while preserving ease of manufacture through automated process integration.
Data Source
Figure 1A
Figure 1B~1D
Figure 1E~1L
AI summary
Method and apparatus for forming an annular composite structure is provided. The apparatus includes an annular shaped tool and a forming head. The annular shaped tool includes a forming surface of a select cross-sectional geometry. The forming head is configured to form continuous ply layers one ply at a time circumferentially about the forming surface of the tool. The method comprises steps of applying continuous ply layers one at time on a forming surface of an annular tool that has a select cross-sectional geometry; and forming the ply layers on the full circumference annular tool with a forming head.